![]() The blue area represents a cross section through the airfoil. In this restoration example, the interface allows asymmetric profile correction on both the pressure (concave) and suction (convex) faces of a compressor airfoil profile. Help sheets and programming wizards guide the user using through the process of setting up a new component on the machine and entering all relevant digitizing and machining parameters. Data points can either be captured individually or continuously streamed at speeds as fast as 100,000 points per second, which translates to digitizing speeds as fast as 6 meters per minute.Īdaptive machining software offers a range of digitizing and machining strategies to suit various applications and machine tool configurations. Data gathered from the device are captured directly into a high-speed, analog-to-digital converter in the attendant computer. TTL’s LDS–100 system uses a laser digitizing head that installs in the machine’s spindle as well as a high-speed computer interface card. This is particularly helpful in situations when large surfaces need to be recreated rapidly and efficiently, such as the repair of gas turbine components. ![]() Compared with touch probes, the speed with which a laser can capture data provides a dramatic reduction in scanning times. Touch probes or laser scanning probes allow the adaptive machining process to account for plastic deformation and worn components prior to machining. Although manual blending may produce a component that’s cosmetically pleasing, the component’s geometric accuracy may not meet specifications. This is particularly important in stress-critical turbine applications in which wall thicknesses must be maintained. In addition, blend accuracy can often be achieved without compromising component thickness or geometric form. Using adaptive machining, operations such as chord restoration, leading-edge profiling, airfoil surface machining and blending back into the original material can be performed automatically. In either case, the added material must be contoured to bring the airfoil surface back to its original shape. Blisk repair often starts by building up the airfoil surface at the tip and leading edge or completely replacing individual airfoil sections via electron-beam welding. Repair is necessary when a blisk becomes physically damaged in service (from a bird strike, for example) or due to routine wear. However, their complex geometries make the blisk repair process equally as difficult as manufacturing new ones. They are more expensive and complex to manufacture than single-blade designs, so there is significant interest in developing cost-effective methods to repair them. Blisks are primarily produced using five-axis machining operations to achieve the required cycle times, accuracy and surface finish. Blisks have become widely integrated into rotor designs in recent years because they offer significant performance advantages over single-blade designs. The one-piece blisk design replaces the traditional series of individual blades that make up the stages of a rotor. Adaptive machining technology is also effective in repairing blisks (bladed disks).
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